Flexible Rotary Encoder Sensor with Curved Substrate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Rotary encoders with separate light-emitting and light-receiving elements on different substrates face challenges in positioning and stress issues due to substrate deformation, leading to potential failures in the connecting portions, especially when using flexible substrates.
Innovation Solution
A sensor design where the light-emitting and light-receiving units are integrated on a flexible substrate with a curved or bent shape, and a plate support member is attached to keep electronic components in a plane, facilitating easier positioning and reducing stress on the connecting portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the light-emitting element and light-receiving element are provided on separate substrates, then the sensor can be manufactured with modular components, but positioning between the light-emitting range and light-receiving range becomes complex and time-consuming
Solution Approach 1:
The patent combines the light-emitting element and light-receiving element onto a single flexible substrate, eliminating the need for complex positioning between separate substrates. The substrate integrates both functional units with their connecting portions, reducing assembly complexity and positioning time while maintaining modular manufacturability through the flexible substrate's inherent flexibility.
2Ease of operation
If a flexible substrate is used to enable easy deformation for processing, then the substrate can be easily shaped and processed, but stress is applied to the connecting portions between electronic components and wiring, causing cracks and failures
Solution Approach 1:
The patent employs a curved or bent substrate configuration where the substrate is folded or curved to position the light-emitting and light-receiving elements in close proximity. This curvature design allows the flexible substrate to achieve the necessary three-dimensional positioning while distributing mechanical stress away from the connecting portions, preventing cracks and maintaining reliability during deformation and processing.
3Ease of manufacture
If the substrate is made flexible to facilitate processing and positioning, then the substrate can be easily deformed for assembly, but the connecting portions between the flexible substrate and electronic components become vulnerable to stress-induced failures
Solution Approach 1:
The patent introduces a support structure or rigidifying layer as an intermediary between the flexible substrate and the electronic components (light-emitting and light-receiving elements). This intermediary element provides mechanical support to the connecting portions, reducing stress concentration while allowing the substrate to maintain its flexibility for easy processing and positioning during assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design simplifies the positioning of the generating and detecting units and decreases the likelihood of failures in the connecting portions between the flexible substrate and electronic components, enhancing the reliability of the sensor.
Implementation Method 1
a generating unit that generates a predetermined object to be detected; a detecting unit that detects the object to be detected generated by the generating unit
Data Source
AI summary
A sensor including: a generating unit; a detecting unit that detects the object to be detected generated by the generating unit; and a substrate at which the generating unit and the detecting unit are provided. The substrate is a flexible substrate that includes a first portion provided with the generating unit and a second portion provided with the detecting unit, the first portion and the second portion being integrated, and that takes a curved shape or a bent shape in which a surface of the first portion at which the generating unit is provided and a surface of the second portion at which the detecting unit is provided face each other. A plate support member is attached to a back-side surface of at least one of the surface of the first portion and the surface of the second portion.